Chrysler PT Cruiser. Manual — part 705
Front Crankshaft Oil Seal Installer 6780
Combustion Leak Tester C-3685-A
Cooling System Tester 7700
Pressure Transducer CH7059
Cylinder Compression Pressure Adaptor 8116
DRB III
T
with PEP Module OT-CH6010A
9 - 100
ENGINE 2.4L DOHC
PT
ENGINE 2.4L DOHC (Continued)
AIR CLEANER ELEMENT
REMOVAL
(1) Unfasten clasps on sides of air cleaner housing
cover. Lift cover off air cleaner housing (Fig. 19).
(2) Remove filter element.
(3) If necessary, clean the inside of the air cleaner
housing.
INSTALLATION
(1) Install new filter element.
(2) Place cover over air cleaner housing. Snap
clasps in place.
AIR CLEANER HOUSING
REMOVAL
(1) Disconnect the throttle body air inlet hose/
clean air hose from the air cleaner housing (Fig. 20)
or (Fig. 21) and (Fig. 22).
(2) Pull air cleaner housing straight up to remove.
(3) Remove the inlet duct from the air cleaner
housing.
INSTALLATION
(1) Install inlet duct to the air cleaner housing.
(2) Make sure the rubber grommets, for the air
cleaner housing lower pins, are in place when rein-
stalling the air cleaner housing. The rubber grom-
mets mount to the PDC bracket (Fig. 20) or (Fig. 21).
(3) Push air cleaner housing down while aligning
pins into the grommets.
(4) Connect the throttle body air inlet hose/clean
air hose to the air cleaner housing (Fig. 20) or (Fig.
21) and (Fig. 22).
Fig. 19 Air Cleaner Cover
Fig. 20 Air Inlet System
Fig. 21 Air Inlet System - 2.4L Turbo
1 - CLEAN AIR HOSE
2 - AIR CLEANER HOUSING
3 - FRESH AIR INLET DUCT
4 - PDC MOUNTING BRACKET
PT
ENGINE 2.4L DOHC
9 - 101
CYLINDER HEAD
DESCRIPTION
The cross flow designed, aluminum cylinder head
contains dual over-head camshafts with four valves
per cylinder (Fig. 23). The valves are arranged in two
in-line banks. The intake valves face toward the
front of the vehicle. The exhaust valves face the dash
panel. The cylinder head incorporates powdered
metal valve guides and seats. The cylinder head is
sealed to the block using a multi-layer steel head
gasket and retaining bolts.
Integral oil galleries provide lubrication passages
to the hydraulic lash adjusters, camshafts, and valve
mechanisms.
DIAGNOSIS AND TESTING
CYLINDER HEAD GASKET
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
• Loss of engine power
• Engine misfiring
• Poor fuel economy
Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
• Engine overheating
• Loss of coolant
• Excessive steam (white smoke) emitting from
exhaust
• Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50–70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
Fig. 22 Clean Air Hose - 2.4L Turbo
1 - CLEAN AIR HOSE
2 - TURBOCHARGER
Fig. 23 Cylinder Head and Camshafts
1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
9 - 102
ENGINE 2.4L DOHC
PT
AIR CLEANER HOUSING (Continued)
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE
PRESSURE
BUILT
UP,
BY
CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester’s pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL - CYLINDER HEAD
(1) Perform fuel system pressure release procedure
before attempting any repairs (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE).
(2) Remove clean air hose and air cleaner housing
(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR
CLEANER HOUSING - REMOVAL).
(3) Disconnect negative cable from battery.
(4) Drain cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(5) Remove upper intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
REMOVAL).
(6) Remove fastener attaching dipstick tube to
lower intake manifold (Fig. 24) or (Fig. 25).
(7) Turbocharger equipped vehicles: Remove
lower intake manifold support bracket (Fig. 25).
(8) Disconnect the fuel supply line quick-connect at
the fuel rail assembly (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/QUICK CONNECT FITTING -
STANDARD PROCEDURE).
(9) Remove heater tube support bracket from cyl-
inder head.
(10) Remove
upper
radiator
hose.
Disconnect
heater hoses from thermostat housing.
(11) Disconnect engine coolant temperature sensor
connector.
(12) Remove accessory drive belts (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(13) Disconnect exhaust pipe from manifold.
(14) Turbocharger equipped vehicles: (Fig. 26)
• Remove turbocharger heat shields
• Remove elbow support bracket
Fig. 24 Dipstick Tube
1 - DIPSTICK TUBE
2 - SCREW
Fig. 25 Lower Intake Manifold Support Bracket -
2.4L Turbo
1 - UPPER INTAKE MANIFOLD
2 - LOWER INTAKE MANIFOLD
3 - SUPPORT BRACKET
4 - DIPSTICK TUBE SCREW
PT
ENGINE 2.4L DOHC
9 - 103
CYLINDER HEAD (Continued)
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